Multicellular folding box structures



July 26, 1960 M. l. WILLIAMSON 2,946,498

MULTICELLULAR FOLDING BOX STRUCTURES Filed July 19, 1957 2 Sheets-Sheet l mmvron Mars/ml! I William so M ATTORNEY I J ly 26, 19 0 M. I. WILLIAMSON 2,946,498

MULTICELLULAR FOLDING BOX STRUCTURES Filed July 19, 1957 2 Sheets-Sheet 2 INVENTOR. Mars/1a 1/ 1' Williamson A TTOR/VEY 2346,4 93 Patented July 26, 1960 2,946,498 MULTICELLULAR FOLDHQG BOX STRUCTURES Marshall I. Williamson, New Haven, Conn., assignor to Federal Paper Board Company, Inc., Bogota, N.J., a corporation of New York Filed July 19, 1957, Ser. No. 673,002

8 Claims. (Cl. 229-28) In the packaging of fragile items of the aforementioned character it is desirable to protect the packaged item in such a way as to prevent damage by contact with other objects, for example, another package, an enclosing crate, a table surface on which the package is placed, a package stacked on top, or an adjacent article contained in the same package. Good protection is afiorded by a package which holds the fragile article with a cushioning grip and which extends a sufiicient distance above and below the article to prevent damage by physical contact.

Taking, as a specific example, Christmas ornaments, or eggs, the enclosing box structure should extend a sulficient distance above and below the egg or ornament. Damage by crushing from the sides is prevented by a cushioning support about the egg or ornament capable of absorbing shock or yielding under impact sufficiently to prevent the force from acting on the packaged item.

Articles should be held in the multicellular package in such a way that they do not rattle. This involves a snug support about the sides of the packaged article. Difiiculties arise, if the articles are not of uniform size and also where the article is highly fragile, as is the case in Christmas ornaments made of blown glass. In order to package such items successfully, the folding box should be constructed to grip the packaged article gently so as to prevent rattling, but not so firmly as to create the danger of crushing when the article is inserted into, or removed from, its cell in the box structure.

In the packaging of electric light bulbs and photoflash bulbs it is desirable to permit testing of the bulbs without removing them from the package. In the case of light bulbs this is done by connecting them in a light circuit, and in the case of flash bulbs this is done by a resistance test during which a Weak current is passed through the bulb insufiicient to set off the flash bulb.

The present invention provides a multicellular folding box structure which is particularly suited to the packaging of articles of the aforementioned nature. It provides a secure but gentle grip on the merchandise by cells which are sufliciently flexible to adapt themselves to variations in size of the merchandise. The cellular structure provides physical protection above, beneath and around the packaged item, permits easy removal of the packaged article from the multicellular structure, and permits packaged light bulbs to be tested without removal from the package.

These and various other features and advantages of the invention will appear more fully from the detailed description which follows accompanied by drawings showing, for the purpose of illustration, a preferred embodimerit of the invention. The invention also resides in certain new and original features of construction and combination of elements hereinafter set forth and claimed.

Although the characteristic features of the invention which are believed to be novel will be particularlypointed out in the claims appended hereto, the invention itself, its objects and advantages, and the manner in which it may be carried out, may be better understood by referring to the following description taken in connection with the accompany drawings, forming a part of it, in which:

Figure 1 is a plan view of a flat blank from which a cellular folding structure embodying the invention may be assembled, the back surface of the board facing the observer;

Figure 2 shows the blank of Figure 1 after preparatory folding and gluing operations transforming the blank into a fiat collapsed structure ready for expansion into multicellular box form;

Figure 3 is a perspective view of the assembled multicellular box;

Figure 4 is a vertical section taken on line 4-4 of Figure 3 and showing the seating of a light bulb in the box structure; and

Figure 5 is an elevational end view of the box.

In the following description and in the claims various details will be identified by specific names for convenience. The names, however, are intended to be generic. Corresponding reference characters refer to corresponding parts in the several figures of the drawing.

The drawings accompanying, and forming part of, this specification disclose certain specific details of the invention for the purpose of explanation of broader aspects of the invention, but it is understood that the details may be modified in various respects without departure from the principles of the invention and that the invention may be applied to other structures thanthe one shown.

The blank A shown in Figure 1 may be cut and scored in multiple from large sheets or rolls of foldable board. The blank is of rectangular shape and involves no waste in the cutting from larger sheets or rolls. It comprises a first wall panel 11, a top panel 12, a second wall panel 13, a bottom panel 14, an inner glue panel 15, an intermediate panel ]16, and a glue lap 17. The several panels are articulated to one another along parallel fold lines 18, 19, 20, 21, 22. and 23, of which fold lines 18 and 19 may be termed top fold lines, 20 and 21 bottom fold lines, and 23 a glue lap fold line.

According to preferred practice the top panel has at least one longitudinal folding crease extending through it which in the finished box provides a ridge or gable. In the illustrated form of blank one longitudinal fold line 24 is provided, symmetrically arranged with respect to the fold lines 18 and 19. The top wall panel also has a number of apertures 25 cut therein by removing stock in the blanking'operation. The spacing of the apertures 25 represents the spacing of the centers of the individual cells in the finished box structure. Similar blanked apertures 26 are provided in the bottom panel 14, the spacing of apertures 26 being equal to the spacing of the apertures 25.

Further apertures are provided in the intermediate panel 16. In the preferred embodiment these apertures are formed by star cuts 27 supplemented by peripheral crease forming means such as interrupted cuts 28. p ,j

The top panel 12 comprises transverse cuts 29 extend ing at right angles to the top fold lines 18 and 19. Preferably, although not necessarily, these cuts 29 extend into the body of the adjoining wall panels 11 and 13.

Peripheral scores defining the mouths of the cells to be formed extend about the apertures 25 in the top panel 12 These scores comprise fold lines '30 and 31 forming a polygon about the apertures 25. The area within the polygon is traversed by further fold lines 32, radiating from the aperture25 .and extending to the peripheral fold lines which constitute the polygon. It will be observed that the longitudinal folding crease 24 also constitutes a fold line radiating from the apertures 25.

The assembly of a cellular folding box structure from the blank A may proceed as follows:

' Adhesive a is first applied to the marginal end area of the wall panel 11 and also to the glue lap 17, whereafter the'blank is folded at the bottom fold line 21 to bring the glue lap 17 into adhesive engagement with the panel 13. The blank is then folded along the top fold line 19 to seal the adhesive area of the side wall panel with the inner glue panel 15. These folding and gluing operations result in the formation of a tubular fiat collapsed structure A shown in Figure 2.

' The structure A may be shipped and stored in collapsed fiat condition and requires a minimum of space. It may quickly be expanded into hollow tubular form, followed by the formation of cells in the top panel 12 by a'series of operations about to be described. These operations may be performed manually or by mechanical equipment. Mechanical means for forming the cellular structure form the subject matter of my copending application Serial No. 702,360, filed December 12, 1957.

- In order to square the blank A pressure is exerted against the edges 19 and 21 of the structure A causing the structure to assume hollow tubular shape of substantially rectangular cross-section in which the panel 16 forms an internal partition.

Next, inwardly directed force is exerted against the side Walls 11 and 13 at, or adjacent, the top fold lines 18 and 19, the direction of the force being substantially in the plane of the top panel 12. Such compressive force causes the top panel 12 to buckle and crease at its central longitudinal folding crease represented in the illustrated box by line 24. The top panel then forms a gable or roof structure, as is seen in Figures 3 and 5.

It is elementary that a gabled roof structure has greater resistance to caving-in than a flat roof and this phenomenon is taken advantage of in the formation of the cellular structure to insure against caving-in of the entire top panel except at certain weakened areas to be depressed to form web-walled cells while preserving the gable or peak shape of the top panel at areas intermediate the cells.

' The cells are formed by a downwardly directed force applied to the areas within the aforementioned polygons weakened by cuts and fold lines. The cell forming force is preferably applied immediately adjacent the apertures 25 and causes the circumscribed panel portions to cave in and assume a depending position. The collapse is aided by the radiating fold lines 32. The resulting structure is shown in Figure 3. The mouth of each cell is defined by the fold lines 30 from which substantially triangular panel portions depend in the fashion of a skirt. The bottom end of the skirt is defined by the edge of the cut 29. The portions of inal position are triangular panels 38 having the top fold lines '18 and 19 as bases and being joined at the apexes at '24.

In the preferred and illustrated form of construction the skirt portions are folded back upon the side Walls at the fold lines 31, so as to present a cushioning skirt or liner extending about the entire circumference of the cell opening. Due to the resistance of the stock to folding, the skirt remains slightly funnel-shaped even after insertion of merchandise and presents a somewhat larger dithe roof structure remaining in the orig-' ameter at the mouth than at the bottom edge of the skirt. This detail is shown in Figure 4 in which the skirt portions of adjoining cells are spaced at s. The resiliency of the web structure offers the advantage of providing a cushioning support for packaged articles, represented in Figure 4 by a flash bulb 33 having a glass portion 34 and a base 35. The center of the substantially spherical glass portion lies at 36 and the bottom edge 29 of the skirt lies below the center. This position would normally produce a tendency to eject the sphere 34 from the cell aperture. The semi-circular cutouts 25 counteract such tendency by engaging the sphere a distance h above the center 36, thus tending to push the bulb down into the cell.

In the seated position the bulb rests on the center partition 1 6 which may be creased along a center fold line 37. In seated position the peaks 24 extend a safe margin m above the top of the glass portion 34 and protect the bulbs against damage, even if the package were turned upside down.

It is readily seen that the resiliency of the skirt portion of the cells also compensates for diiference in the diameter of the packaged article, if such differences occur. On the other hand, highly delicate articles, such as Christmas tree balls or similar ornaments of blown glass .may be packaged in slightly oversized cells in which they fit rather loosely except near the fully seated position where the resilient bottom edge 29 of the skirt grips them, the cutout portion 25 hearing against an area of the article above the center to retain the article safely in the cell.

The flash bulbs 33 are first loosely inserted into the cellular structure and are centered to some extent by the funneling action of the cell walls. The cutouts 25 perform a further centering operation prior to depression of the bulbs into seated position. This operation is described in detail in my aforementioned application Serial No. 702,360 and involves an action for moving the base 35 into accurately centered position with regard to the star cuts or apertures 27, 28 in the panel 16. This action is obtained as follows:

It was previously mentioned that the tubular blank is subjected to compressive force which results in the formation of a gable or gables. The compressive force is maintained at least to a limited degree during the depressing operation which then leads to the formation of the cells as described above. After depressing of the skirt portion into depending position from the triangular top panel portion 38 the angularity of the funnel structure may be controlled by the degree of compressive force exerted at the top of the side walls. If the force is increased, the skirt portions tend to assume a substantially vertical position. If the force is relieved the skirt portions form a relatively flat funnel in which the two semi-circular cutouts '25 of each cell approach each other.

This action is utilized for centering the bulb bases. The compressive force is relieved temporarily, causing the semi-circularedges 25 of each cell to engage the base 35 of the bulb which at this moment rests loosely at the very mouth of the cells. The edges 25 accurately center the base 35 above the star out aperture in the panel 16. Subsequent downwardly directed force exerted on the bulbs causes the bulbs to assume the fully seated position shown in Figure 4.

In inserted position the base 35 is accessible through the aperture 26 in the bottom. An electric circuit may be established through this aperture for the purpose of testing the bulb. Also, the bulb may be ejected by, finger pressure exerted through the aperture 26, so that it is not necessary to handle the bulb at its fragile glass portion 34. a

In the packaging of spherical articles such as Christmas balls the same basic construction shown in Figure 4 is of advantage, except that the height H of the center panel 16 above the bottom panel 14 may be reduced to a fraction. The aperture 26 permits the ball to be ejected by finger pressure frorn'underneath and it is not necessary to grasp the ball at the portion accessible through the cell aperture in order to remove it.

It is readily seen that the cellular structure provided by the invention offers advantages in the packaging of delicate items. Modifications of the package for specific users are readily made.

What is claimed is:

l. A folding box structure for the packing of light bulbs, comprising, in combination, a pair of opposite side walls, a cellular top structure between said side walls, said top structure providing a plurality of cellular apertures and comprising pairs of oppositely disposed upwardly slanted panel portions articulated to said side walls along their bases and having an apex opposite the base, the apexes of oppositely slanted panel portions being joined at a ridge lying above said bases, and skirt panel portions depending from said upwardly slanted panel portions and forming substantially tubular walls about said cellular apertures, said tubular walls being adapted to retain light bulbs between them; a lamp base supporting panel extending between said side walls below said top structure, said lamp base supporting panel having apertures therein in line with said cellular apertures, the apertures in the lamp base supporting panel being adapted to receive light bulb bases; and a bottom panel below said supporting panel, said bottom panel being articulated to said side walls and having apertures in it in line with the apertures in the supporting panel, through which bottom panel apertures the bases of light bulbs packaged in said box structure are accessible.

2. A cellular folding box structure comprising, in combination, a pair of opposite side walls; a top panel between, and articulated to, said side walls along top fold lines, said top panel including a central longitudinal folding score forming an elevated ridge lengthwise of the structure, spaced blanked apertures cut from the stock of the top panel in line with said folding score, and cuts transverse to said folding score and in line with said apertures, said top panel further including peripheral folding scores about said apertures, said peripheral folding scores forming polygons having the said apertures as centers, and radial fold lines radiating from said apertures and extending to said peripheral folding scores, the panel portions within said polygons being deflectable into substantially tubular skirt shape, forming cells in which said transverse cuts form a bottom edge and the edges of said blanked apertures form an upwardly arched article-grasping edge above said bottom edge; and a bottom panel articulated to said side walls at bottom fold lines.

3. A cellular folding box structure comprising, in combination, a pair of opposite side walls; a cellular top panel between, and articulated to said side walls along top fold lines, said top panel including a central longitudinal folding score along which said top panel is folded to form a gable, said top panel further including spaced apertures centered with respect to said gable, and cuts transverse to said gable and in line with said apertures, peripheral folding scores about said apertures, said peripheral folding scores being at least eight in number of which four lie withinthe side walls, namely a first pair lying in one side wall and a second pair lying in the other side wall, each pair forming a V extending from and symmetrically arranged with respect to, said cuts, said peripheral scores forming at least eight-sided polygons having said apertures as centers, and radial fold lines radiating from said apertures and extending to said peripheral folding scores, the stock of the top panel and the side walls within said polygons being deflected into substantially tubular skirt shape to form cells articulated to said side walls along said Vs in which cells said transverse cuts form a bottom edge and in which the edges of said apertures form a raised article grasping edge above said bottom edge; a bottom panel articulated to said side walls at bottom fold lines; and an intermediate panel extending from side wall to side wall between said top panel and said bottom panel, said intermediate panel and said bot- 6 tom panel having apertures therein in line with the cells in said top panel.

4. A cellular folding box structure as set forth in claim 3 in which the apertures in the intermediate panel are star-cut and the apertures in the bottom panel are blanked.

5. A cellular folding box structure comprising, in combination, a pair of opposite side walls; a top panel articulated to said sidewalls along top fold lines, said top panel having a plurality of spaced apertures blanked therefrom arranged in line substantially midway between said top fold lines and having a centrally disposed longitudinal folding score between said top fold lines extending through the center of said apertures, said top panel further including peripheral folding scores about said apertures, said peripheral folding scores being at least eight in number of which four lie within the side walls, namely a first pair lying in one side wall and a second pair lying in the other side wall, each pair forming a V, said peripheral scores forming at least eight-sided polygons having said apertures as centers, and cuts substantially at right angles to said top fold lines, said cuts bisecting said Vs and extending through said apertures, the panel portions within said polygons being traversed by folding scores and deflectable into substantially skirt shape to form article receiving cells articulated to said side walls along said Vs in which cells said cuts form a lower skirt edge and in which the edges of said apertures form upwardly arched article grasping edges; and a bottom panel articulated to said side walls at bottom fold lines.

6. A cellular folding box structure comprising, in combination, a pair of opposite side walls; a top panel articulated to said side walls along top fold lines, said top panel having a plurality of spaced apertures blanked therefrom arranged in line substantially midway between said top fold lines and having a central longitudinal folding score along which the panel is folded to form elevated peaks extending lengthwise of the box structure, said top panel further including peripheral folding scores about said apertures, said peripheral folding scores being at least eight in number of which four lie within the side walls, namely a first pair lying in one side wall and a second pair lying in the other side wall, each pair forming a V, said peripheral scores forming at least eight-sided polygons having said apertures as centers, and cuts substantially at right angles to said top fold lines, said cuts bisecting said Vs and extending through said apertures, the panel portions within said polygons being traversed by folding scores and deflected into depending skirt shape to form article, receiving cells articulated to said side walls along said Vs in which cells said cuts form a lower skirt edge and in which the edges of said apertures form upwardly arched article grasping edges; and a bottom panel articulated to said side walls at bottom fold lines.

7. A folding box structure for the packaging of light bulbs, comprising, in combination, a pair of opposite side walls, a cellular top structure between said side walls, said top structure providing a plurality of cellular apertures and comprising pairs of oppositely disposed substantially triangular upwardly slanted panel portions articulated to the side walls along their bases, opposite triangular panel portions having a common apex point, the apex points of the structure lying centered and above said bases on a line extending the length of the box structure, said top structure further comprising skirt panel portions depending from said triangular panel portions and forming cellular walls of at least eight-sided cell apertures, said skirt panel portions constituting four cell sides arranged in opposite pairs, each pair being articulated along a fold line depending from the respective apex point, the distance between said opposite last named fold lines representing a diagonal of the cell aperture, further skirt panel portions depending from, and lying folded back upon, said sides walls along lines forming Vs in the side walls, said further panel portions being articulated to said first skirt panel portions and constituting four further cell sides; a bottom panel between, and articulated to,

said side walls; and an intermediate panel extending between said side walls intermediate said top structure and said bettom panel, said intermediate panel having apertures therein in line with said cellular apertures, the

apertures in the intermediate panel being adapted to 're- 5 ceive light bulb bases. I

3. A folding box structure as set forth in the preceding claim 7 in which the apertures in the intermediate panel are formed by star cuts.

References Cited inthe file of this patent UNITED STATES PATENTS 

